U.S. patent application number 14/623272 was filed with the patent office on 2015-06-11 for methods and systems for controlling an electric motor.
The applicant listed for this patent is Regal Beloit America, Inc.. Invention is credited to ROGER CARLOS BECERRA, Ludovic Andre Chretien, David Allen Clendenen, Yao Da, Glen C. Young.
Application Number | 20150162859 14/623272 |
Document ID | / |
Family ID | 51207212 |
Filed Date | 2015-06-11 |
United States Patent
Application |
20150162859 |
Kind Code |
A1 |
BECERRA; ROGER CARLOS ; et
al. |
June 11, 2015 |
METHODS AND SYSTEMS FOR CONTROLLING AN ELECTRIC MOTOR
Abstract
Methods and systems for controlling an electric motor are
provided. An electric motor controller is configured to be coupled
to an electric motor. The controller includes a rectifier, an
inverter coupled to the rectifier, and a control unit coupled to
the inverter. The rectifier is configured to rectify an alternating
current (AC) input voltage to produce a pulsed direct current (DC)
voltage that drops to approximately zero during each cycle when the
AC input voltage transits zero. Energy is stored on a load coupled
to the motor when AC input voltage is available. The inverter is
configured to receive the DC voltage and to provide a conditioned
output voltage to the motor. The control unit is configured to
manage energy transfer between the motor and the load such that the
motor generates positive torque when the DC voltage supplied to the
inverter has approximately 100% voltage ripple.
Inventors: |
BECERRA; ROGER CARLOS; (Fort
Wayne, IN) ; Chretien; Ludovic Andre; (Columbia City,
IN) ; Young; Glen C.; (Fort Wayne, IN) ;
Clendenen; David Allen; (Fort Wayne, IN) ; Da;
Yao; (Fort Wayne, IN) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Regal Beloit America, Inc. |
Beloit |
WI |
US |
|
|
Family ID: |
51207212 |
Appl. No.: |
14/623272 |
Filed: |
February 16, 2015 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
13749242 |
Jan 24, 2013 |
8981686 |
|
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14623272 |
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Current U.S.
Class: |
318/400.23 |
Current CPC
Class: |
H02P 21/24 20160201;
H02P 6/10 20130101; H02M 5/458 20130101 |
International
Class: |
H02P 6/10 20060101
H02P006/10 |
Claims
1.-26. (canceled)
27. An electric motor controller configured to be coupled to an
electric motor, said motor controller comprising: a rectifier
configured to rectify an alternating current (AC) input voltage to
produce a pulsed direct current (DC) voltage that drops to a value
of approximately zero during each cycle when the AC input voltage
transits a value of zero, wherein energy is stored on a load
coupled to the electric motor when AC input voltage is available;
an inverter coupled to an output of said rectifier, said inverter
configured to receive the DC voltage and to provide a conditioned
output voltage to the electric motor; and a control unit coupled to
said inverter and configured to manage energy transfer between the
electric motor and the load such that the electric motor generates
positive torque when the DC voltage supplied to said inverter has
approximately 100% voltage ripple.
28. The motor controller in accordance with claim 27, wherein said
control unit is further configured to maintain torque of the
electric motor above a predefined torque threshold when the AC
input voltage transits a value of zero.
29. The motor controller in accordance with claim 27, wherein said
control unit is further configured to increase a rotational speed
of the electric motor when input voltage is available, wherein the
increased rotational speed generates energy that is stored on the
load as inertia.
30. The motor controller in accordance with claim 29, wherein the
inertia limits speed variations of the electric motor to enable
continuing torque production when input voltage is unavailable.
31. The motor controller in accordance with claim 27, wherein said
control unit is further configured to maintain positive torque of
the electric motor when the AC input voltage transits a value of
zero by using energy stored in the motor windings.
32. The motor controller in accordance with claim 27, wherein to
manage the energy transfer, said control unit is configured to
control current flowing to the electric motor to produce positive
torque when the AC input voltage is one of approaching zero and
equal to zero.
33. The motor controller in accordance with claim 32, wherein to
control current to the electric motor, said control unit is
configured to induce a flux linkage component of current to
maintain a torque component of the current above zero.
34. The motor controller in accordance with claim 33, wherein said
control unit is further configured to induce the flux linkage
component of current while reducing stator winding losses in the
electric motor.
35. The motor controller in accordance with claim 33, wherein said
control unit is further configured to induce the flux linkage
component of current while reducing torque ripple in the electric
motor.
36. The motor controller in accordance with claim 33, wherein said
control unit is further configured to induce the flux linkage
component of current while manipulating torque harmonics to reduce
audible noise in the electric motor.
37. The motor controller in accordance with claim 27, further
comprising a DC link positioned between said rectifier and said
inverter.
38. The motor controller in accordance with claim 37, further
comprising a voltage clamping device coupled across said DC link,
said voltage clamping device configured to protect said controller
against an over-voltage condition.
39. The motor controller in accordance with claim 27, further
comprising a capacitor coupled across said DC link, said capacitor
configured to mitigate switching frequency harmonics.
40. A method of controlling an electric motor using a motor
controller, the electric motor configured to be coupled to a power
supply and to a load, said method comprising: rectifying an
alternating current (AC) input voltage received from the power
supply to produce a pulsed direct current (DC) voltage, wherein the
DC voltage drops to a value of approximately zero during each half
cycle when the AC input voltage transits a value of zero, wherein
energy is stored on the load coupled to the electric motor when AC
input voltage is available; receiving, by an inverter coupled to an
output of the rectifier, the DC voltage to provide a conditioned
output voltage to the electric motor; and controlling, by a control
unit coupled to the inverter, energy transfer between the electric
motor and the load such that the electric motor generates positive
torque when the DC voltage supplied to the inverter is one of
approaching zero and equal to zero.
41. The method in accordance with claim 40, further comprising:
increasing, by the control unit, a rotational speed of the electric
motor when input voltage is available; and storing energy generated
by the increased rotational speed on the load as inertia.
42. The method in accordance with claim 40, wherein controlling the
energy transfer comprises controlling current flowing to the
electric motor to produce positive torque when input voltage is one
of approaching zero and equal to zero.
43. The method in accordance with claim 42, wherein controlling
current flowing to the electric motor comprises inducing a flux
linkage component of current to maintain a torque component of the
current above zero.
44. A system comprising: an electric motor; and a motor controller
coupled to said electric motor, said motor controller comprising: a
rectifier configured to rectify an alternating current (AC) input
voltage to produce a pulsed direct current (DC) voltage that drops
to a value of approximately zero during each cycle when the AC
input voltage transits a value of zero, wherein energy is stored on
a load coupled to said electric motor when AC input voltage is
available; an inverter coupled to an output of said rectifier, said
inverter configured to receive the DC voltage and to provide a
conditioned output voltage to said electric motor; and a control
unit coupled to said inverter, said control unit configured to
manage energy transfer between said electric motor and the load
such that said electric motor generates positive torque when the DC
voltage supplied to said inverter is one of approaching zero and
equal to zero.
45. The system in accordance with claim 44, wherein said control
unit is further configured to increase a rotational speed of said
electric motor when input voltage is available, wherein the
increased rotational speed generates energy that is stored on the
load as inertia.
46. The system in accordance with claim 44, wherein to manage the
energy transfer, said control unit is configured to control current
flowing to the electric motor by inducing a flux linkage component
of current to maintain a torque component of the current above zero
to produce positive torque when the AC input voltage is one of
approaching zero and equal to zero.
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] The present application is a continuation application of
U.S. application Ser. No. 13/749,242, filed Jan. 24, 2013, the
entire disclosure of which is hereby expressly incorporated herein
by reference.
BACKGROUND OF THE DISCLOSURE
[0002] The field of the invention relates generally to electric
motors, and more specifically, to methods and systems for operating
electric motors.
[0003] Typical electric motor systems include a motor controller
and an electric motor. The motor controller receives power from an
alternating current (AC) power supply, and applies it to a
rectifier and to filter capacitors to generate a smoothed direct
current (DC) voltage. The motor controller then supplies the DC
voltage to the electric motor, which uses the power to drive a
load.
[0004] Filter capacitors typically used in motor controllers
include electrolytic capacitors with high capacitances (about 1000
.mu.F). The high capacitances cause the capacitors of the motor
controller to be bulky and expensive. These filter capacitors
necessitate a larger motor controller and may reduce the lifespan
of the motor controller.
BRIEF DESCRIPTION OF THE DISCLOSURE
[0005] In one aspect, an electric motor controller configured to be
coupled to an electric motor is provided. The controller includes a
rectifier, an inverter coupled to the rectifier, and a control unit
coupled to the inverter. The rectifier is configured to rectify an
alternating current (AC) input voltage to produce a pulsed direct
current (DC) voltage that drops to approximately zero during each
cycle when the AC input voltage transits zero. Energy is stored on
a load coupled to the motor when AC input voltage is available. The
inverter is configured to receive the DC voltage and to provide a
conditioned output voltage to the motor. The control unit IS
configured to manage energy transfer between the motor and the load
such that the motor generates positive torque when the DC voltage
supplied to the inverter has approximately 100% voltage ripple
[0006] In another aspect, a method is provided of controlling an
electric motor using a motor controller. The electric motor is
configured to be coupled to a power supply and to a load. The
method includes rectifying an alternating current (AC) input
voltage received from the power supply to produce a pulsed direct
current (DC) voltage, wherein the DC voltage drops to a value of
approximately zero during each half cycle when the AC input voltage
transits a value of zero, wherein energy is stored on the load
coupled to the electric motor when AC input voltage is available.
The method also includes receiving, by an inverter coupled to an
output of the rectifier, the DC voltage to provide a conditioned
output voltage to the electric motor. The method further includes
controlling, by a control unit coupled to the inverter, energy
transfer between the electric motor and the load such that the
electric motor generates positive torque when the DC voltage
supplied to the inverter is one of approaching zero and equal to
zero.
[0007] In yet another aspect, a system is provided that includes a
motor controller coupled to an electric motor. The motor controller
includes a rectifier, an inverter coupled to an output of the
rectifier, and a control unit coupled to the inverter. The
rectifier is configured to rectify an alternating current (AC)
input voltage to produce a pulsed direct current (DC) voltage that
drops to a value of approximately zero during each cycle when the
AC input voltage transits a value of zero. Energy is stored on a
load coupled to the electric motor when AC input voltage is
available. The inverter is configured to receive the DC voltage and
to provide a conditioned output voltage to the electric motor. The
control unit is configured to manage energy transfer between the
electric motor and the load such that the electric motor generates
positive torque when the DC voltage supplied to the inverter is one
of approaching zero and equal to zero.
BRIEF DESCRIPTION OF THE DRAWINGS
[0008] FIG. 1 is a functional diagram of a motor controller that
may be used for operating an electric motor.
[0009] FIG. 2 is a block diagram of an exemplary controller that
may be used with the motor controller shown in FIG. 1.
[0010] FIG. 3 is an operational diagram of the exemplary motor
controller shown in FIG. 1, in which energy may be stored on a load
coupled to an electric motor.
[0011] FIG. 4 illustrates a graphical relationship between rail
voltage, torque, and rotational speed the exemplary electric motor
controller shown in FIG. 1.
[0012] FIG. 5 illustrates multiple performance benefits achieved by
using the exemplary motor controller shown in FIG. 1.
[0013] FIG. 6 is a functional diagram of an exemplary embodiment of
a motor controller.
[0014] FIG. 7 is a functional diagram of an exemplary embodiment of
a motor controller.
[0015] FIG. 8 is a functional diagram of an exemplary embodiment of
a motor controller.
[0016] FIG. 9 is a flow chart of an exemplary method of operating
an electric motor using the motor controller shown in FIG. 1.
[0017] FIG. 10 is a block diagram of an exemplary embodiment of the
motor controller shown in FIG. 1 used an air moving control
system.
DETAILED DESCRIPTION OF THE DISCLOSURE
[0018] FIG. 1 is a functional diagram of a motor controller 100
that may be used for operating an electric motor 102. In the
exemplary embodiment, motor controller 100 includes a rectifier
104, a controller 106, and an inverter 108. Motor controller 100 is
coupled to a power supply 110 for receiving input power to drive
electric motor 102. Electric motor 102 is coupled to and drives a
load 112.
[0019] In the exemplary embodiment, power supply 110 supplies a
single-phase alternating current (AC) voltage to motor controller
100. However, power supply 110 may supply three-phase AC, direct
current (DC) voltage, or any other type of input voltage that
enables motor controller 100 to function as described herein.
Rectifier 104 receives an AC input voltage from a power supply 110
and rectifies it to produce a pulsed DC voltage. Inverter 108
conditions the pulsed DC voltage, and supplies it to electric motor
102, which uses the power to drive load 112. In the exemplary
embodiment, inverter 108 converts the pulsed DC voltage to a
three-phase AC voltage. Alternatively, inverter 108 converts the
pulsed DC voltage to any type of voltage that enables motor
controller to function as described herein.
[0020] In some embodiments, motor controller 100 includes a
low-capacitance capacitor 114 for storing small amounts of energy
when input voltage is available. Capacitor 114 may have a
capacitance between about 0.1 .mu.F/kW and about 10 .mu.F/kW. The
use of bulky, unreliable electrolytic filter capacitors in motor
controller 100 is avoided. In some embodiments, capacitor 114 is
configured to filter out switching frequency harmonics of electric
motor 102. In other embodiments, the low-capacitance of capacitor
114 reduces inrush input current to electric motor 102. Further,
capacitor 114 facilitates motor controller 100 increasing line
input power factor.
[0021] Motor controller 100 also includes a voltage sensor 116
coupled across capacitor 114. Voltage sensor 116 is configured to
measure a DC link voltage being output by rectifier 104. Voltage
sensor 116 provides the DC link voltage measurement to controller
106 for use in controlling electric motor 102 to produce torque
when DC link voltage has a 100% voltage ripple.
[0022] FIG. 2 is a block diagram of an exemplary algorithm
implemented by controller 106 (shown in FIG. 1). Because there is
no filter capacitor in motor controller 100 (shown in FIG. 1), DC
link voltage drops to zero each time the AC input voltage drops to
zero. Typically, when DC link voltage drops to zero, also referred
to as a 100% voltage ripple, regeneration and braking occur in
electric motor 102, which may cause undesired effects in electric
motor 102. In the exemplary embodiment, controller 106 is
configured to control electric motor 102 (shown in FIG. 1) to
produce torque when input voltage is one of approaching zero and
equal to zero. More specifically, in the exemplary embodiment,
controller 106 is configured to control electric motor 102 to
produce torque when DC link voltage has a 100% voltage ripple.
[0023] In the exemplary embodiment, controller 106 is coupled to
rectifier 104 and to inverter 108 (both shown in FIG. 1).
Controller 106 receives three-phase motor current measurements
I.sub.a, I.sub.b, and I.sub.c from at least one current sensor 200,
which is coupled to electric motor 102. Controller 106 includes a
d-q conversion module 202, a current command generator 204, a PI
controller 206, an a-b-c conversion module 208, and a modulator
210.
[0024] Current measurements I.sub.a, I.sub.b, and I.sub.c are
converted to a d-q reference frame by d-q conversion module 202 to
obtain a d-axis current I.sub.d, related to a flux linkage
component of the current and a q-axis current I.sub.q related to a
torque component of the current. I.sub.d and I.sub.q are sent to PI
controller 206. Current command generator 204 generates a d-axis
command I.sub.d* and a q-axis command I.sub.q*, which are both also
sent to PI controller 206.
[0025] PI controller 206 prepares voltage values V.sub.d and
V.sub.q to be applied to electric motor 102 such that the d-axis
current value I.sub.d and the q-axis current value I.sub.q become
equal to the d-axis current command I.sub.d* and the q-axis current
command I.sub.q*. V.sub.d and V.sub.q are converted back to a
three-phase coordinate system by a-b-c conversion module 208, which
provides the three-phase voltage values V.sub.a, V.sub.b, and
V.sub.c to modulator 210. Modulator 210 outputs the voltage values
V.sub.a, V.sub.b, and V.sub.c to inverter 108 as a
pulse-width-modulated (PWM) signal. Modulator 116 outputs the PWM
signal with a frequency, angle, and/or duty cycle to provide
suitable power to electric motor 102.
[0026] In the exemplary embodiment, controller 106 is configured to
control electric motor 102 to produce torque when input voltage is
one of approaching zero and equal to zero. In controlling electric
motor 102, controller 106 is configured to maintain torque of
electric motor 102 above a predetermined level when input voltage
is zero. More specifically, in the exemplary embodiment, controller
106 is configured to control current flowing to electric motor 102
such that electric motor 102 produces torque when input voltage is
one of approaching zero and equal to zero.
[0027] In one embodiment, to control current flowing to electric
motor 102, controller 106 is configured to induce the flux linkage
component I.sub.d of the current to maintain the torque component
I.sub.q of the current above zero while reducing loss of energy
stored in the stator windings of electric motor 102. In another
embodiment, to control current flowing to electric motor 102,
controller 106 is configured to induce the flux linkage component
I.sub.d of the current to maintain the torque component I.sub.q of
the current above zero while reducing torque ripple in electric
motor 102. In yet another embodiment, to control current flowing to
electric motor 102, controller 106 is configured to induce the flux
linkage component I.sub.d of the current to maintain the torque
component I.sub.q of the current above zero while manipulating
torque harmonics to reduce audible noise in electric motor 102.
[0028] In the exemplary embodiment, controller 106 is implemented
in one or more processing devices, such as a microcontroller, a
microprocessor, a programmable gate array, a reduced instruction
set circuit (RISC), an application specific integrated circuit
(ASIC), etc. Accordingly, in this exemplary embodiment, d-q
conversion module 202, current command generator 204, PI controller
206, a-b-c conversion module 208, and modulator 210 are constructed
of software and/or firmware embedded in one or more processing
devices. In this manner, controller 106 is programmable, such that
instructions, intervals, thresholds, and/or ranges, etc. may be
programmed for a particular electric motor 102 and/or operator of
electric motor 102. One or more of d-q conversion module 202,
current command generator 204, PI controller 206, a-b-c conversion
module 208, and modulator 210 may be wholly or partially provided
by discrete components, external to one or more processing
devices.
[0029] FIG. 3 is an operational diagram of motor controller 100 in
which inertial energy may be stored on electric motor 102. FIG. 4
illustrates a graphical relationship between rail voltage 400,
torque 402 produced by rotation of electric motor 102, and
rotational speed 404 of load 112. Motor controller 100 is
substantially similar to motor controller 100 (shown in FIG. 1),
and as such, components shown in FIGS. 3 and 4 are labeled with the
same reference numbers used in FIG. 1.
[0030] An increase in input voltage to motor controller 100 results
in an increase in armature current. The increase in armature
current results in an increase in torque production by electric
motor 102, resulting in increased acceleration. As rotational speed
of electric motor 102 increases, induced voltage on electric motor
102 also increases. As a result, current and torque gradually
decrease until torque again equals the load or induced voltage
equals the applied voltage. A decrease in voltage results in a
decrease of armature current and a decrease in torque produced by
electric motor 102, causing electric motor 102 to slow down.
Induced voltage may momentarily be higher than the applied voltage,
causing regenerative braking in electric motor 102.
[0031] Because only a small capacitor 114 is used in motor
controller 100, large amounts of voltage are not be stored on the
DC link of motor controller 100. Rather, in the exemplary
embodiment, motor controller 100 stores energy on rotational load
112, which is coupled to a rotatable shaft (not shown) of electric
motor 102. More specifically, in the exemplary embodiment, load 112
is a mechanical energy storage device. For example, in one
embodiment, load 112 may be a blower and/or fan used in an air
moving control system.
[0032] During operation, in the exemplary embodiment, rectifier 104
rectifies the AC line input voltage received from power supply 110
into a pulsed AC. When AC line input voltage is available (i.e.,
increasing in graph 400), controller 106 is configured to store
energy in rotating load 112 at inertia. More specifically, when
input voltage is available, the torque increases (graph 402),
causing the rotational speed (graph 404) of load 112 to also
increase, as is shown in FIG. 4. Inertia stored on rotating load
112 is represented by the equation
J * .DELTA. .omega. 2 2 , ##EQU00001##
where J represents inertia of load 112 and .DELTA..omega.
represents a change in speed of load 112 with respect to time. In
the exemplary embodiment, the inertia of load 112 limits speed
variations of electric motor 102, which enables torque production
to continue when input voltage is unavailable.
[0033] In one embodiment, while input voltage is available,
processing unit also stores small amounts of voltage in capacitor
114. When the AC line input voltage approaches zero, controller 106
controls capacitor 114 to provide the stored voltage to electric
motor 102. The amount of energy stored in capacitor 114 is
represented by the equation
C * .DELTA. U 2 2 , ##EQU00002##
where C represents a capacitance of capacitor 114 and .DELTA.U
represents a change in voltage in capacitor 114 with respect to
time.
[0034] As the input voltage begins to drop, torque produced on load
112 by electric motor 102 turns into rotational speed. As AC line
input voltage approaches zero, controller 106 manages energy
transfer from load 112 to electric motor 102 (represented by dashed
arrows). More specifically, controller 106 controls current flowing
to electric motor 102 such that electric motor 102 continues
producing torque when input voltage to electric motor 102
approaches zero or equals zero. To do so, controller 106 implements
an algorithm (shown in FIG. 2) to produce a signal that induces a
flux linkage component of current to maintain a torque component of
the current above zero. More specifically, controller 106 injects a
negative d-axis current signal to electric motor 102 as AC line
input voltage approaches zero to maintain q-axis current at a
positive level. In an alternative embodiment, controller 106 also
manages energy transfer from capacitor 114 to electric motor 102
(represented by dashed arrows). These energy transfers enable
electric motor 102 to operate while input voltage is low or
unavailable during each phase of the pulsed DC.
[0035] FIG. 5 illustrates multiple performance benefits achieved by
using motor controller 100 (shown in FIG. 1) as opposed to using
known motor controllers (not shown) using large electrolytic
capacitors. Performance of known motor controller using 1000 .mu.F
electrolytic filter capacitors is represented by the line
containing diamonds. Performance of motor controller 100 using a 10
.mu.F capacitor 114 (shown in FIG. 1) is represented by the line
containing squares; using a 5 .mu.F capacitor 114 is represented by
the line containing triangles; and using a 1 .mu.F capacitor 114 is
represented by the line containing "X's".
[0036] Graph 500 compares power factor of electric motor 102 (shown
in FIG. 1) to different power levels of electric motor 102. The
power factor of electric motor 102 using motor controller 100 is
noticeably higher than the power factor of an electric motor using
known electrolytic capacitor motor controllers, regardless of which
capacitance of capacitor 114 is used.
[0037] Graph 502 compares input current to operating power of
electric motor 102. Input current is inversely related to the power
factor shown in graph 500. Graph 502 shows that electric motor 102
with motor controller 100 operates at the same power level, while
using less input current than known motor controllers.
[0038] Graph 504 compares total harmonic distortion (THD) to
electric motor 102 operating power. In the exemplary embodiment,
THD using motor controller 100 is reduced by approximately 50% over
THD using known motor controllers.
[0039] Graph 506 compares efficiency of electric motor 102 to
operating power. Motor controller 100 does not filter the rectified
AC line input voltage, so current levels in motor controller 100
are large compared to known motor controllers. Accordingly, up to
about 6% efficiency may be sacrificed using motor controller 100.
However, this decrease in efficiency is acceptable in some
applications when compared to the increased power factor, reduced
THD, and reduced size of motor controller 100.
[0040] FIG. 6 is a functional diagram of an exemplary embodiment of
a motor controller 600. Components of motor controller 600 that are
identical to components of motor controller 100 (shown in FIG. 1)
are described using the same reference characters as in FIG. 1.
[0041] In the exemplary embodiment, motor controller 600 includes
rectifier 104, controller 106, and inverter 108. Motor controller
600 is coupled to power supply 110 for receiving input power to
drive electric motor 102. Electric motor 102 is coupled to and
drives a load 112. Controller 106 implements the algorithm
described in FIG. 2.
[0042] In the exemplary embodiment, power supply 110 supplies a
single-phase alternating current (AC) voltage to motor controller
600. However, power supply 110 may supply three-phase AC, DC
voltage, or any other type of input voltage that enables motor
controller 600 to function as described herein. Rectifier 104
receives an AC input voltage from power supply 110 and rectifies it
to produce a pulsed DC voltage. Inverter 108 conditions the pulsed
DC voltage, and supplies it to electric motor 102, which uses the
power to drive load 112. In the exemplary embodiment, inverter 108
converts the pulsed DC voltage to a three-phase AC voltage.
Alternatively, inverter 108 converts the pulsed DC voltage to any
type of voltage that enables motor controller to function as
described herein.
[0043] In the exemplary embodiment, motor controller 600 includes
capacitor 114 for storing small amounts of energy when input
voltage is available. Capacitor 114 has a capacitance between about
0.1 .mu.F/kW and about 10 .mu.F/kW. The use of bulky, unreliable
electrolytic filter capacitors in motor controller 600 is avoided.
In some embodiments, capacitor 114 is configured to filter out
switching frequency harmonics of electric motor 102. In other
embodiments, the low-capacitance of capacitor 114 reduces inrush
input current to electric motor 102. Further, capacitor 114
facilitates motor controller 600 increasing line input power
factor. Voltage sensor 116 (shown in FIG. 1) may also be provided
across capacitor 114 for measuring DC link voltage being output by
rectifier 104. Voltage sensor 116 provides the DC link voltage
measurement to controller 106 for use in controlling electric motor
102 to produce torque when DC link voltage has a 100% voltage
ripple.
[0044] In the exemplary embodiment, motor controller 600 also
includes a voltage clamping device 602 coupled across a DC link of
motor controller 600. Voltage delivered to inverter 108 may be very
large due to the low-capacitance of capacitor 114, which may cause
the rating of inverter 108 to be exceeded. Voltage clamping device
602 is configured to protect motor controller 600 from over-voltage
conditions. In the exemplary embodiment, voltage clamping device
602 is a metal oxide varistor (MOV). In alternative embodiments,
voltage clamping device 602 may be any device capable of providing
over-voltage protection.
[0045] FIG. 7 is a functional diagram of an exemplary embodiment of
a motor controller 700. Components of motor controller 700 that are
identical to components of motor controller 100 (shown in FIG. 1)
are described using the same reference characters as in FIG. 1.
[0046] In the exemplary embodiment, motor controller 700 includes
rectifier 104, controller 106, and inverter 108. Motor controller
700 is coupled to power supply 110 for receiving input power to
drive electric motor 102. Electric motor 102 is coupled to and
drives a load 112. Controller 106 implements the algorithm
described in FIG. 2.
[0047] In the exemplary embodiment, power supply 110 supplies a
single-phase AC voltage to motor controller 700. However, power
supply 110 may supply three-phase AC, DC voltage, or any other type
of input voltage that enables motor controller 700 to function as
described herein. Rectifier 104 receives an AC input voltage from
power supply 110 and rectifies it to produce a pulsed DC voltage.
Inverter 108 conditions the pulsed DC voltage, and supplies it to
electric motor 102, which uses the power to drive load 112. In the
exemplary embodiment, inverter 108 converts the pulsed DC voltage
to a three-phase AC voltage. Alternatively, inverter 108 converts
the pulsed DC voltage to any type of voltage that enables motor
controller to function as described herein.
[0048] In the exemplary embodiment, motor controller 700 includes
capacitor 114 for storing small amounts of energy when input
voltage is available. Capacitor 114 has a capacitance between about
0.1 .mu.F/kW and about 10 .mu.F/kW. The use of bulky, unreliable
electrolytic filter capacitors in motor controller 700 is avoided.
In some embodiments, capacitor 114 is configured to mitigate
switching frequency harmonics of electric motor 102. In other
embodiments, the low-capacitance of capacitor 114 reduces inrush
input current to electric motor 102. Further, capacitor 114
facilitates motor controller 700 increasing line input power
factor. Voltage sensor 116 (shown in FIG. 1) may also be provided
across capacitor 114 for measuring DC link voltage being output by
rectifier 104. Voltage sensor 116 provides the DC link voltage
measurement to controller 106 for use in controlling electric motor
102 to produce torque when DC link voltage has a 100% voltage
ripple.
[0049] In the exemplary embodiment, motor controller 700 also
includes a diode 702 coupled in series with a capacitor 704. Diode
702 and capacitor 704 are coupled to the DC side of rectifier 104.
Diode 702 isolates input line voltage as it drops to zero.
Together, diode 702 and capacitor 704 provide a constant voltage to
be delivered to a low-voltage power supply 706. In the exemplary
embodiment, low-voltage power supply 706 provides power for
electronics of motor controller 700, such as, for example,
controller 106. Additionally, capacitor 704 makes power supply 706
independent of main DC voltage variations in motor controller
700.
[0050] FIG. 8 is a functional diagram of an exemplary embodiment of
a motor controller 800. Components of motor controller 800 that are
identical to components of motor controller 100 (shown in FIG. 1)
are described using the same reference characters as in FIG. 1.
[0051] In the exemplary embodiment, motor controller 800 includes
rectifier 104, controller 106, and inverter 108. Motor controller
800 is coupled to power supply 110 for receiving input power to
drive electric motor 102. Electric motor 102 is coupled to and
drives a load 112. Controller 106 implements the algorithm
described in FIG. 2.
[0052] In the exemplary embodiment, power supply 110 supplies a
single-phase AC voltage to motor controller 800. However, power
supply 110 may supply three-phase AC, DC voltage, or any other type
of input voltage that enables motor controller 800 to function as
described herein. Rectifier 104 receives an AC input voltage from
power supply 110 and rectifies it to produce a pulsed DC voltage.
Inverter 108 conditions the pulsed DC voltage, and supplies it to
electric motor 102, which uses the power to drive load 112. In the
exemplary embodiment, inverter 108 converts the pulsed DC voltage
to a three-phase AC voltage. Alternatively, inverter 108 converts
the pulsed DC voltage to any type of voltage that enables motor
controller to function as described herein.
[0053] In the exemplary embodiment, motor controller 800 includes
capacitor 114 for storing small amounts of energy when input
voltage is available. Capacitor 114 has a capacitance between about
0.1 .mu.F/kW and about 10 .mu.F/kW. The use of bulky, unreliable
electrolytic filter capacitors in motor controller 800 is avoided.
In some embodiments, capacitor 114 is configured to filter out
switching frequency harmonics of electric motor 102. In other
embodiments, the low-capacitance of capacitor 114 reduces inrush
input current to electric motor 102. Further, capacitor 114
facilitates motor controller 800 increasing line input power
factor. Voltage sensor 116 (shown in FIG. 1) may also be provided
across capacitor 114 for measuring DC link voltage being output by
rectifier 104. Voltage sensor 116 provides the DC link voltage
measurement to controller 106 for use in controlling electric motor
102 to produce torque when DC link voltage has a 100% voltage
ripple.
[0054] In the exemplary embodiment, motor controller 800 also
includes a second rectifier 802 coupled in parallel to a capacitor
804. Second rectifier 802 and capacitor 804 are coupled between
power supply 110 and rectifier 104. Together, second rectifier 802
and capacitor 804 provide a constant voltage to be delivered to a
low-voltage power supply 806. In the exemplary embodiment,
low-voltage power supply 806 provides power for electronics of
motor controller 800, such as, for example, controller 106.
[0055] FIG. 9 is a flow chart 900 of a method of operating an
electric motor, such as electric motor 102 (shown in FIG. 1) using
motor controller 100 (shown in FIG. 1). In the exemplary
embodiment, electric motor 102 is coupled to a load 112 (shown in
FIG. 1) and to a power supply, such as power supply 110 (shown in
FIG. 1).
[0056] In the exemplary embodiment, motor controller 100 receives
902 a measured amount of current in electric motor 102. The amount
of current is measured by at least one current sensor 200 (shown in
FIG. 2) coupled to electric motor 102 and to motor controller
100.
[0057] In the exemplary embodiment, motor controller 100 then
controls 904 current flowing to electric motor 102 such that
electric motor 102 produces positive torque when input voltage is
one of approaching zero and equal to zero.
[0058] In one embodiment, to control current flowing to electric
motor 102, controller 106 induces a flux linkage component I.sub.d
of the current to maintain a torque component I.sub.q of the
current above zero while reducing loss of energy stored in the
stator windings of electric motor 102.
[0059] In another embodiment, to control current flowing to
electric motor 102, controller 106 is configured to induce the flux
linkage component I.sub.d of the current to maintain the torque
component I.sub.q of the current above zero while reducing torque
ripple in electric motor 102.
[0060] In yet another embodiment, to control current flowing to
electric motor 102, controller 106 is configured to induce the flux
linkage component I.sub.d of the current to maintain the torque
component I.sub.q of the current above zero while manipulating
torque harmonics to reduce audible noise in electric motor 102.
[0061] FIG. 10 is a block diagram of an exemplary embodiment of
motor controller 100 shown in FIG. 1 in an air moving control
system 1000. System 1000 is an air moving system, such as a
residential heating, ventilation and air conditioning (HVAC)
system, a light industrial HVAC system, or a clean room filtering
system. While described herein as being used in an HVAC system,
motor controller 100 may be used in other applications, including,
but not limited to, swimming pool pumps, laundry machine motors,
and gas pre-mix motors. System 1000 includes an interface circuit
1002 electrically coupled to a system controller 1004, for example
a HVAC system controller, and a main unit 1006, for example a HVAC
unit. Main unit 1006 includes components 1008 and electric motor
1010. In one embodiment, electric motor 1010 is a motor configured
to rotate a blower. Electric motor 1010 includes motor controller
100 including a processing unit (shown in FIG. 2) and a memory (not
shown) containing an electric motor drive program. In one
embodiment, system controller 1004 is connected to a thermostat
1012. Thermostat 1012 includes a plurality of settings, or modes,
such as low heat, high heat, cooling, dehumidify, and continuous
fan. Additionally, thermostat 1012 measures a temperature in a
predetermined space or location and transmits an electrical signal
representing the measured temperature to system controller
1004.
[0062] System controller 1004 controls main unit 1006 via interface
circuit 1002. Interface circuit 1002 receives control signals in
the form of input voltage signals from system controller 1004 and
translates the signals to signals suitable for controlling by
electric motor 1010. Typically, circuits within system 1000 operate
at a different voltage level than does electric motor 1010.
Therefore interface circuit 1002 is utilized for communications
between system controller 1004 and electric motor 1010. Such
interfaces typically control electric motors using pulse width
modulation (PWM) by continuously adjusting motor speed.
[0063] The translated signals are transmitted to motor controller
100 of electric motor 1010, and a torque of electric motor 1010 is
varied in accordance with the adjusted voltage outputs. Electric
motor 1010 is mechanically connected to a blower 1014. In one
embodiment, blower 1014 includes a detection module 1016 which
provides signals, for example signals indicative of a speed of
rotation of blower 1014, to system controller 1004.
[0064] In operation, as motor controller 100 varies the torque of
electric motor 1010, controller 106 monitors and manages energy
storage on a load 112 (shown in FIG. 1). In the exemplary
embodiment, load 112 is blower 1014. The torque applied to electric
motor 1010 translates into rotational speed of blower 1014. When
input voltage is available, mechanical energy in the form of
inertia of blower 1014 is stored. When input voltage becomes low or
approaches zero, controller 106 manages energy transfer from blower
1014 back to electric motor 1010.
[0065] The described embodiments provide a cost savings to the
manufacturer and ultimately to the consumer as electrolytic filter
capacitors are eliminated from a motor controller of an electric
motor. Additionally, reliability of such systems increases as there
are fewer components within the system. Moreover, the described
embodiments reduce total harmonic distortion and increase the power
factor of the electric motor in which they are installed.
[0066] A technical effect of the methods and systems described
herein may include one or more of: (a) rectifying an alternating
current (AC) input voltage received from the power supply to
produce a pulsed direct current (DC) voltage, wherein the DC
voltage drops to a value of approximately zero during each half
cycle when the AC input voltage transits a value of zero, wherein
energy is stored on the load coupled to the electric motor when AC
input voltage is available; (b) receiving, by an inverter coupled
to an output of the rectifier, the DC voltage to provide a
conditioned output voltage to the electric motor; and (c)
controlling, by a control unit coupled to the inverter, energy
transfer between the electric motor and the load such that the
electric motor generates positive torque when the DC voltage
supplied to the inverter is one of approaching zero and equal to
zero.
[0067] This written description uses examples to disclose the
invention, including the best mode, and also to enable any person
skilled in the art to practice the invention, including making and
using any devices or systems and performing any incorporated
methods. The patentable scope of the invention is defined by the
claims, and may include other examples that occur to those skilled
in the art. Such other examples are intended to be within the scope
of the claims if they have structural elements that do not differ
from the literal language of the claims, or if they include
equivalent structural elements with insubstantial differences from
the literal languages of the claims.
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